Process of manufacturing a textile fabric for pocket materials having no stitched seam



1966 MASAJI ITAKURA 3,286,739

PROCESS OF MANUFACTURING A TEXTILE FABRIC FOR POCKET MATERIALS HAVING NO STITCHED SEAM Filed Oct. 25, 1962 5 Sheets-Sheet 1 J7 25 21 P19. E

[4 J5 fi V L l T MLJ 1 l NVENTOR fins/9J1 IIQKURH ATI'O RN EY 5 Nov. 22, 1966 MASAJI ITAKURA 3,286,739

PROCESS OF MANUFACTURING A TEXTILE FABRIC FOR POCKET MATERIALS HAVING NO STITCHED SEAM Filed Oct. 25, 1962 5 Sheets-Sheet 2 INVENTOR fmsnrl ITHKURH BY M ATTORNEY5 Nov. 22, 1966 MASAJI ITAKURA 3,286,739

PROCESS OF MANUFACTURING A TEXTILE FABRIC FOR POCKET MATERIALS HAVING NO STITCHED SEAM Filed Oct. 25, 1962 5 Sheets-Sheet 3 INVENTOR Mas/9n Iran wen BYHMM ATTORNEY-5' United States Patent PROCESS OF MANUFACTURING A TEXTILE FABRIC FOR POCKET MATERIALS HAVING N0 STITCHED SEAM Masaji Itakura, 3 Ekoda, 3-chome, Nakano-ku,

Tokyo, Japan Filed Oct. 25, 1962, Ser. No. 232,948 1 Claim. (Cl. 139-389) This invention relates to a method for making pockets of clothes, utilizing the double cloth weaving or hollow cloth weaving for the process of producing the pocketmaterial fabric.

Pockets are conventionally fabricated by folding a single piece of cloth and by sewing up the meeting edges together so that the cloth will take a shape of a bag open at one edge. Such a pocket has a drawback, in service, of easily developing holes when and if the threads used in the stitched seams should break. In the normal service of pockets in place on clothes, articles are often put into and taken out of pockets, hands are inserted into and pulled out of them just as often, and, each time a pocket is so used, the stitched threads in the seams become tensioned. In course of time, threads wear and tear due to the repeated tension and finally break, thus initiating a development of a hole in the pocket. The hole will be come large enough to permit an article to slip through, presenting inconvenience and nuisance which are experienced frequently in our daily life. If a break occurs in the interlaced part of the fabric, the woven yarns will undo and the structure of the fabric will be increasingly destroyed, starting from the cut or break.

The main object of this invention is to provide a method of producing a fabric material for making pockets having no stitched seams, by weaving required parts of the fabric of double cloth, in single layer during the manufacturing process of textile fabric, in such a way that the fabric so woven results in individual pieces of material for pockets when it is cut into segments, and that the pocket material so obtained has the two layers meet and merge together along the parts into a single layer woven integral with two layer parts of the double cloth, there being no stitch of thread. Since the single layer part is accomplished by interlacing great many yarns in the pocket material of this invention, the pocket so made is structurally strong and eliminates the possibility of developing holes due to breakage of such as threads in the stitch.

Another object of this invention is to provide a method of making pocket materials having no stitched seam by using thermoplastic synthetic resin yarns in the singlelayer woven fabric, or at least in those parts of fabric which are to be joined together, so that, after the said fabric is cut into segments of a proper size, each for a single pocket, the cut part can be thermoplastically fused together to be joined, thus preventing a pocket material from being loosened.

Above and other objects and advantages of the present invention, will be made more specific and clearer in the following description set forth in reference to the accompanying drawings which are as follows:

FIG. 1 shows a fabric embodying this invention,

FIG. 2 represents individual pocket materials obtained by cutting the fabric shown in FIG. 1,

FIG. 3 shows an another fabric embodying this invention,

FIG. 4 illustrates an individual pocket material obtained from the fabric of FIG. 3,

FIG. 5 depicts a still another fabric made according to this invention,

FIG. 6 illustrates an individual pocket material obtained from the fabric of FIG. 5, and

ICC

FIGS. 7 and 8 represent a further embodiment of this invention by showing still another fabric and individual pocket material obtained therefrom.

Identical numbers used in the above drawings refer to the identical parts of the fabrics and pocket materials shown.

In FIGS. 1 and 2, the fabric is woven in two layers with parts of it being woven, however, in single layer. These single-layer parts are designated as 11, extending through the width of the fabric; 13 and 14 which are in a similar widthwise line in single layer but are separated by a portion 12 in two-layer weave. This arrangement is repeated along the length of the woven fabric, such that the single-layer part 11 and the broken single-layer parts 13 and 14 occur alternately at regular intervals. The fabric so woven is to be cut at the single-layer parts; namely, 11, 13, 14 and 21 (corresponding to 11), along the cutting line 15 in part 11, line 16 in parts 13 and 14, line 25 in part 21, and also along the cutting line 17 running lengthwise of the fabric at the inside end of the part 14 and perpendicular to the said widthwise cutting lines, to introduce four individual pocket materials a, b, c and d, as shown in FIG. 2, out of that much fabric depicted in FIG. 1. Pocket materials a and b are symmetrical, in each of which the outer edge of the twolayer Weave corresponds to the bottom of the pocket and the two-layer part 12 forms the pocket opening into which a hand may be inserted. The single-layer parts 11, 13 and 21 constitute the side edges. Obviously materials a and b can be used for the side pockets of, for instance, trousers.

As to pocket materials 0 and d, it will be seen that they too are symmetrical, with the fold of the weave constituting the pocket bottom and with the single-layer parts 11, 13 and 21 constituting the pocket edges. These materials can be utilized, for example, for the back pockets of trousers.

In attaching the above pocket materials to the trousers, for instance, the only sewing required is that of stitching the materials to the fabric of the trousers, there being no need of making stitches within the construction of the pocket itself, and therefore the pocket attached to clothes is free from the possibility of developing any hole due to breakage of stitched threads.

The single-layer parts through which cutting lines 15, 16 and 25 run may be made in a different weave or the cutting lines are woven with yarns of a different color, so as to distinguish the cutting lines from the remaining parts and to facilitate the necessary cutting. The edges may be sewed up for reinforcing these parts. The possibility of the fabric tearing and raveling off can be eliminated by using thermoplastic synthetic resin yarns for weaving the single-layer parts and by cutting the synthetic parts of the fabric while heat is applied to the cut so as to fuse the yarns together at the cut edges. The edges 12 and 17 of the two-layer part need not be given a provision for preventing the yarns from raveling off, because these parts are to be stitched to the fabric of, for instance, trousers.

In the process of weaving, the both edges of the fabric may be strengthened by increasing the number of warp or weft yarns or both.

A net weave, gauze weave or any other sparsely interlaced weave may be used in making thebottom, back, front, or any combination thereof, of the pocket material so that the fabric will, in part or in whole, have large meshes through which the dust particles accumulating in the pocket will drop, thus keeping the pocket in clean, cool and sanitary condition at all time.

In the following instances each embodying this invention, the foregoing methods of making distinct the parts to be cut through, of preventing the edges of the fabric from raveling or unweaving, of reinforcing the holded part by increasing the number of yarns, and of making the pocket fabric porous, may be employed singly or in any combination thereof.

Another pocket material shown in FIG. 3 is for the side pockets of clothes and is woven in two layers and, partly, in single layer, such that individual pocket materials line up sidewise and occur continuously along the length of woven fabric. In FIG. 3, part 31 is a singlelayer weave mostly with weft yarns, and 32 and 33 are similar single-layer parts but mostly with Warp yarns. This fabric is to be out along the lines 41, 42, 43 and then individual pocket materials are obtained from each unit portion of the fabric. FIG. 4 illustrates one of the pocket materials so obtained. The entrance of the pocket may be formed by partially cutting off the singlelayer edge part occurring in the direction of warp. It should be noted that the bottom of each pocket, formed by the single-layer part 31 in weft direction is preferably rounded so that in sharp corners dust could accumulate, and also that articles put into the pocket in actual use will tend to locate themselves at the mid-part of the pocket bot-tom, thereby making it easy to take them out of he pocket.

In still another pocket material shown in FIGS. 5 and 6, the fabric is so woven that the part of the material corresponding to the bottom of the pocket has an extra singlelayer portion 51, making the two-layer part rather narrow at the bottom. Such a pocket as this presents an advantage of causing the articles put into the pocket in actual use to collect into the narrow part or bottom cavity, making it unnecessary to grope with ones hand inside the pocket for the articles in there whenever they are to be taken out of the pocket.

FIG. 7 shows another fabric woven essentially in two layers, each unit portion of which comprises two individual materials for front pockets and two similar materials for back pockets. 111 these pocket materials, those parts to be stitched to clothes need not be in single-layer Weave, but other edges parts designated as 61 through 65, inclusive, and 71 are in single layer. The fabric is to be cut through lines 66 through 69, inclusive, and 72 The fabric shown in FIG. 8 is still another embodiment of this invention and contains a plurality of materials for open-top pockets. As in the case of the fabric shown in FIG. 3, this one consists essentially of two-layer fabric crisscrossed by single-layer parts 81 through 84, inclusive, and is to be cut along the lines 91 through 97, inclusive, and each of the segments that result from this cutting is t-o be used as a pocket material with an open top.

What is claimed is:

A method of making seamless pockets for attachment to garments, said method comprising the steps of providing a web of woven fabric woven with a repeat pattern of wide areas of two-layer material united with each other along the longitudinal edges of the web and extending across the width of the web alternating with narrow areas of single-layer material extending transversely of the length of the Web, said narrow areas being formed of single strips extending across the full Width of the web but being interrupted intermediate the longitudinal adges of the web by a portion of said two-layer material alternating with a combination of a single strip made of singlelayer maeerial extending partly across the Width of the web from one longitudinal edge thereof and a pair of strips made of single-layer material and extending partly across the web from the other longitudinal edge thereof, the inner ends of said single strip and said pair of strips in said oombination'being separated from each other by a portion of two-layer material, cutting the web crosswise along each interrupted single strip intermediate the longitudinal edges thereof and also along the single strip and the pair of strips in said combination of strips intermediate the longitudinal edges of the strips in said combinations, and further cutting the web lengthwise intermediate the inner ends of said interrupted single strips and also intermediate the inner ends of the strips in said combination of strips.

References Cited by the Examiner UNITED STATES PATENTS 58,035 9/1866 Kottgen 139-389 303,211 8/1884 Bray 139-389 328,378 10/1885 Bray 139-389 328,379 10/1885 Bray 139-389 355,874 1/1887 Jooss.

358,265 2/ 1 887 Hardenbrook 139-3 89 1,773,967 8/1930 Dreyfus 2.8-1.2 1,871,046 8/1932 Dickie 156-251 1,983,452 12/1934 Gwaltney 139-389 2,035,138 3/1936 Maxfield 28-1.2 2,071,251 2/1937 Carothers 28-1 2,093,425 9/ 1937 Dreyfus 15 6-25 1 2,208,256 7/ 1940 Goldsmith 139-389 2,735,797 2/1956 Schjeldahl 15 6-25 1 2,797,712 7/1957 Shapiro 139-407 X 2,840,117 6/1958 Scruggs 28-73 X 3,033,257 5/1962 Weber 156-251 X FOREIGN PATENTS 346,341 11/1904 France. 1,136,506 12/ 1956 France.

4,642 1879 Great Britain.

521,597 6/ 1940 Great Britain.

830,215 3/1960 Great Britain.

MERVIN STEIN, Primary Examiner.

RUSSELL C. MADER, DONALD W. PARKER,

Examiners. J. KEE CHI, Assistant Examiner. 

